Temperature sensing system

ABSTRACT

A temperature sensing and diagnostics system having a temperature sensor for generating a temperature characteristic and a bitbus includes a field processing module and an auxiliary processing module. The field processing module is adapted for coupling to the temperature sensor and for receiving the temperature characteristic from the temperature sensor. The field processing module includes a field diagnostic component and a field communication component configured for communication over the bitbus and is adapted to generate field operating data including a temperature diagnostic parameter as a function of the temperature characteristic. The auxiliary processing module is configured for communicating with the bitbus and for receiving the field operating data and includes an auxiliary diagnostic component and an auxiliary communication component having a fieldbus interface and a gateway component. The auxiliary processing module is configured for generating auxiliary field data as a function of the field operating data and for communicating the auxiliary field data over a fieldbus.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/605,819, filed on Aug. 31, 2004. This application is also related toU.S. patent application Ser. No. 11/216,379, filed Aug. 31, 2005,entitled DISTRIBUTED DIAGNOSTICS OPERATIONS SYSTEM; U.S. patentapplication Ser. No. 11/216,380, filed Aug. 31, 2005, entitled METHOD OFDIAGNOSING AN OPERATIONS SYSTEM; U.S. patent application Ser. No.11/216,381, filed Aug. 31, 2005, entitled METHOD OF TEMPERATURE SENSING;and PCT patent application PCT/US2005/031289, filed Aug. 31, 2005,entitled OPERATIONS SYSTEM DISTRIBUTED DIAGNOSTIC SYSTEM. Thedisclosures of the above applications are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to a distributed operational system and,more specifically, relates to a distributed thermal sensing system.

BACKGROUND OF THE INVENTION

Manufacturing factories, assembly plants, buildings with temperaturecontrol, semiconductor fabrication plants, facilities with energymanagement systems, and process plants have many systems and operationprocesses that add to the efficient operation of one or more associatedcontrol, maintenance and factory automation systems. Many of theoperational processes can be monitored to ensure proper equipment andprocess functioning and to provide feedback for process control,maintenance (including predictive maintenance), supervisory control anddata acquisition (SCADA), and test and automation systems to identifyprocess problems or potential equipment failures. Monitored processescan include the measurement of temperature, flow, pressure, level,current, power, motion, vibration, fluid properties and equipmentfailure and related data, among others, that are monitored by sensors.

Electronic sensors require additional signal processing of the sensedvariable including the transducing of the variable or othercharacteristics that are transduced into an electrical voltage, current,resonant frequency or digital word that is indicative of thecharacteristic and which can be transmitted to systems. The signalprocessing is usually accomplished by a transmitter connected to thesensor or through electronics directly connected to the sensor by a wireor cable or connected wirelessly.

As one example, temperature is an often measured physical variable orcharacteristic of manufacturing processes. The most common temperaturemeasurement systems utilize thermocouples (TCs), resistance temperaturedevices (RTDs), thermopiles and/or thermistors to sense the physicaltemperature variable. Other temperature sensors can include, by way ofexample, semiconductor based RTDs, diodes, infrared sensors, andresonant quartz sensors.

A typical sensor is wired directly to a single channel of aninput/output (I/O) device. This direct wiring method is commonlyreferred to as point-to-point wiring. In this case, the temperaturesensor provides an electrical output where an electrical parameter suchas a resistance or a voltage changes with changes in a repeatable mannerwith temperature. The I/O device then converts the electrical parameterinto a standard output compatible with a controller or the inputrequirements of a monitoring or controlling device. The output of theI/O device can be analog, such as a voltage or a current, or can bedigital signal or code such as one that conforms to a digital busstandard such as Ethernet TCP/IP, EtherNet/IP, FDDI, ControlNet, Modbus™(a trademark of AEG Schneider Corporation), Profibus, ProfiNet, IEEE802.XX wireless and various fieldbuses or proprietary network protocols.The I/O device used for temperature systems typically converts only oneparameter from a temperature sensor such as the parameter that providesthe physical variable, temperature. In addition to converting thetemperature sensor electrical parameter into a standard output that canbe interfaced to a controller or a monitoring or controlling system, theI/O device can also provide additional signal processing. Such signalprocessing can provide for linearization of the sensor, increasing theoutput level of the sensor (gain), removing stray electrical noise,and/or providing isolation from stray electrical currents. Traditionallytemperature I/O devices are provided by manufacturers such as ActionInstruments and Rochester Instruments.

The functions of simple signal processing of temperature sensorelectrical parameters are well known and are performed by manymanufacturers of temperature I/O device products. One common temperaturesensing system uses a transmitter located adjacent to a thermal process.Transmitters are used in approximately 50% of all thermal systems andprovide signal processing of the electrical parameter, electricalisolation of the sensor from stray electrical and mechanical noiseinputs, linearization and scaling of the electrical output, a localmeans for calibrating the sensor and a standardized output. Traditionalstandardized outputs for transmitter-based systems include a two-wire4-20 mA output, a 10-50 mA output, and a 1-5V output. Traditionaltemperature transmitters are manufactured by companies such asRosemount, ABB Hartmann & Braun, and Honeywell. Transmitter basedsystems are also wired to the I/O device, but the I/O deviceaccommodates only standardized voltage or current inputs and does notprovide additional signal processing of the temperature variable.Commercial standard I/O devices are provided by programmable logicalcontroller suppliers such as Siemens, Allen Bradley and Omron. Digitalcontrol systems suppliers include Emerson Process, Honeywell, Siemens,Invensys, Yokogawa, and ABB. Third parities often provide input/outputinterfaces for digital control systems (DCS) (such as a control systemused in a process control plant such as chemical, refining, electricpower where the materials flow continuously in pipes) or programmablelogic controllers (PLC)'s such as Opto22, Moore Industries, ActionInstruments, and Phoenix (PLCs are often used in factories for thecontrol of discrete events like the manufacture of automobiles orwidgets or process plants where products are made in batches, likepharmaceuticals). The I/O device can perform a multiplexing function andcan convert the temperature signal to a standardized output that can beused by a controller, control systems, or monitoring system. Further,the output from the I/O device is most commonly a digital signal on afieldbus.

Another form of a sensor-transmitter based monitoring system includes amicroprocessor located at or near the sensor. These “smart transmitters”were first introduced in the 1980s and have the ability to output orcommunicate a digital message over a bus. Smart transmitters provide forimproved signal processing and linearization using the microprocessorwith embedded or related software programs. In addition, a digitaloutput is communicated over a bus and enables the smart transmitters tobe wired in a “multi-dropped” fashion that reduces the wiring and thenumber of I/O channels for a particular operational application. Smarttransmitters can communicate digitally to an I/O using HART®, FoundationFieldbus, Profibus PA, or proprietary protocols such as the HoneywellDE, Yokogawa Brain, or Foxboro I/A.

The I/O device used with a smart transmitter converts the digital inputfrom a transmitter to a digital output (usually at a higher baud rateand/or different protocol) that is compatible with a controllerconnected to the output of the I/O device. The digital I/O device doesnot normally provide for signal conditioning of the transmittervariable, but functions as a data concentrator and protocol converter.The integral power supply in the I/O can often provide electrical powerover the wire to the transmitters.

With the introduction of digital smart sensors in the 1980's, thetransmitter and controller manufacturers introduced a plethora ofdigital communication protocols often referred to as fieldbuses.Fieldbus protocols can be used with several types of physical mediaincluding 2 and 4 wire, optical media, wireless, etc. Generally, thelowest speed fieldbus provides a high speed two wire communicationprotocol that can be used to digitally integrate sensors, actuationdevices, controls, monitoring systems and equipment with an operationsor management system. The fieldbus is characterized by low powerconsumption and 32 bit messaging capability built on a standard openprotocol. Fieldbus transmitters and systems provide higher speed (baudrate) buses and have the ability to handle large amounts of data. Atypical data rate for a fieldbus is 31.25 Kbps. Fieldbuses are alsolimited to the delivery of relatively low levels of electrical power toassure that the fieldbus-based transmitters satisfy electrical powerrequirements of intrinsically safe or increased safety electricalindustry standards required for safe operation in process environmentswhere explosive gases may be present.

A fieldbus-based transmitter can be connected to a control system and anenterprise asset management (EAM) system that uses diagnosticsinformation from the transmitter for process, system, transmitter orequipment diagnostics. The fieldbus transmitter has the ability toprovide large amounts of data at data rates of up to 32 kb/s whilelimiting its power consumption to low levels as required forintrinsically safe systems. Typically, manufacturers provide diagnosticsinformation from their transmitter products. The diagnostics informationis produced by the local transmitter by processing electrical parametersoriginating from the sensor to provide diagnostics related to thesensor, the process, the sensor wiring, the transmitter electronics, thewiring, and the digital fieldbus. This diagnostics information usuallyhas standard diagnostic parameters as well as diagnostic parameters thatare different for each manufacturer, but is readily communicateddigitally to and from the fieldbus transmitter over the standardfieldbus to a fieldbus compatible I/O device. The cost of the fieldbustransmitters are often more than twice the price of traditionaltransmitters and are ten to twenty times the price of a sensor.

One fieldbus manufacturer, Rosemount, Inc., developed a protocol that iscalled HART® (Highway Addressable Remote Transducer) that is a hybridprotocol. The HART® protocol provides for a frequency shift keying (FSK)digital signal superimposed over the standard 4-20 mA analog wiringformerly used as the transmitter standard. Rosemount, Inc. donated theHART® protocol to the public domain and HART® is now available to allmanufacturers through The HART® Communication Foundation (HCF). HART® isnow the most frequently used transmitter protocol. A smart HART®-typetransmitter can replace traditional 4-20 mA transmitters without changesin the wiring or I/O device if the user wants only a temperatureparameter. HART® can also provide digital information with an associatedchange in the I/O device. With the advent of the smart digitallycommunicating transmitters, additional information can also becommunicated from the transmitter such as field device tag number,manufacturer's ID, scaling factor, simple electronics diagnostics.

Other digital protocols have also emerged such as Modbus™ and, mostrecently higher speed protocols with the ability to provide distributedcomputing have been introduced. Some fieldbus protocols such as theFoundation fieldbus, ProfiNet and Profibus PA provide for standardizedmessaging and parameters for diagnostics. Other systems provide adiagnostic capability such as a self-validating sensor (SEVA) thatincludes diagnostics alerts.

Fieldbus transmitters are often more than twice as expensive astraditional transmitters, due in part to the more sophisticatedelectronics required to process more parameters and to the complexity ofthe communications signal processing for a fieldbus. Many operational orprocess systems do not require the full capabilities of the fieldbus anddo not justify the high implementation cost, especially when monitoringsimple, less-costly sensors, actuation devices, and discrete devicessuch as contact closures, switches, and/or digital on-off devices. Assuch, there is a need for a simple, less costly system and method thatprovides many of the higher level diagnostic functions available withthe fieldbus technology.

One such alternative for a lower cost operational communication systemis the “bitbus.” A bitbus typically provides 8 bits of messaginginformation. A bitbus can carry relatively high speed messaging at a lowcost. One such bitbus is the DeviceNet™ (a trademark of Open DeviceNet™Vendors Association (ODVA)) that is an extension of an automotivedigital bus, the Car Automation Network (CAN). A second bitbus,AS-Interface (AS-i), was developed in Europe for simple digital orlogical inputs for factory automation systems and is, similarly, verylow cost.

Generally, current bitbus-based devices do not include extensivediagnostic capabilities, do not provide signal conditioning that isoften required in a harsh operating environment, and do not interfacewell with higher level operational systems. Due to the limited bandwidthof the bitbus, current bitbus systems do not include digital diagnosticsinformation processing of diagnostic parameters that are contained inthe digital bitbus message from a sensor or actuating device.

SUMMARY OF THE INVENTION

Various embodiments of the present invention provide an improveddistributed operations system for monitoring, controlling, diagnosing oracquiring data from field devices that operate over a bitbus andinterface to a fieldbus.

In one aspect of the invention, a temperature sensing and diagnosticssystem having a temperature sensor for generating a temperaturecharacteristic and a bitbus includes a field processing module and anauxiliary processing module. The field processing module is adapted forcoupling to the temperature sensor and for receiving the temperaturecharacteristic from the temperature sensor. The field processing moduleincludes a field diagnostic component and a field communicationcomponent configured for communication over the bitbus and is adapted togenerate field operating data including a temperature diagnosticparameter as a function of the temperature characteristic. The auxiliaryprocessing module is configured for communicating with the bitbus andfor receiving the field operating data and includes an auxiliarydiagnostic component and an auxiliary communication component having afieldbus interface and a gateway component. The auxiliary processingmodule is configured for generating auxiliary field data as a functionof the field operating data and for communicating the auxiliary fielddata over a fieldbus.

In another aspect of the invention, a temperature sensing and diagnosticsystem has a temperature sensor for generating a sensed energy level anda bitbus. A field processing module is adapted for coupling to thetemperature sensor and for receiving the sensed energy level from thetemperature sensor. The field processing module includes a fielddiagnostic component and a field communication component configured forcommunication over the bitbus. The field processing module is adapted tocompare the received sensed energy level to a predefined energy leveland to identify a temperature diagnostic event when the differencebetween the sensed energy level and the predefined energy level isindicative of the temperature diagnostic event. The field processingmodule is also adapted to generate field operating data including atemperature diagnostic parameter as a function of the identifiedtemperature diagnostic event. An auxiliary processing module isconfigured for communicating with the bitbus and for receiving the fieldoperating data. The auxiliary processing module includes an auxiliarydiagnostic component and an auxiliary communication component having afieldbus interface and a gateway component. The auxiliary processingmodule is configured for generating auxiliary field data as a functionof the field operating data and for communicating the auxiliary fielddata over a fieldbus.

In still another aspect of the invention, a temperature sensing anddiagnostic system has a temperature sensor for generating a temperaturecharacteristic and a bitbus. A field processing module is adapted forcoupling to the temperature sensor and for receiving the temperaturecharacteristic from the temperature sensor. The field processing moduleincludes a field diagnostic component and a field communicationcomponent configured for communication over the bitbus. The fieldprocessing module is adapted to generate field operating data includinga temperature diagnostic parameter as a function of the temperaturecharacteristic. An auxiliary processing module is configured forcommunicating with the bitbus and for receiving the field operatingdata, said auxiliary processing module including an auxiliary diagnosticcomponent and an auxiliary communication component having a fieldbusinterface and a gateway component configured for converting the receivedfield operating data in a bitbus format to auxiliary field data in afieldbus format. The auxiliary processing module is configured forgenerating auxiliary field data as a function of the field operatingdata and for communicating the auxiliary field data over a fieldbus to atemperature management system communicatively coupled to the fieldbus.

In yet another aspect of the invention, a temperature sensing systemwith integrated diagnostics having a bitbus includes a temperaturesensor for generating a temperature characteristic, and a field devicefor generating a field operating characteristic. A first fieldprocessing module is configured for receiving the temperaturecharacteristic from the first temperature sensor and includes a firstfield diagnostic component and a first field communication componentconfigured for communication over the bitbus. The first field processingmodule is configured for generating first field operating data includinga first field diagnostic parameter as a function of the temperatureoperating characteristic. A second field processing module is configuredfor receiving the field operating characteristic from the field device,the second field processing module having a second field diagnosticcomponent and a second field communication component configured forcommunication over the bitbus. The second field processing module isconfigured for generating second field operating data including a secondfield diagnostic parameter as a function of the second operatingcharacteristic. An auxiliary processing module is configured forcommunicating with the bitbus and receiving the first field operatingdata from the first field processing module and the second fieldoperating data from the second field processing module. The auxiliaryprocessing module includes an auxiliary diagnostic component and anauxiliary communication component having a fieldbus interface and agateway component. The auxiliary processing module is configured forgenerating auxiliary field data as a function of at least one of thefirst field operating data and the second field operating data and forcommunicating the auxiliary field data over a fieldbus.

In another aspect of the invention, a temperature sensing system withintegrated diagnostics having a bitbus includes a first temperaturesensor configured for generating a first temperature characteristic, asecond temperature sensor configured for generating a second temperaturecharacteristic, and a field processing module for receiving the firsttemperature characteristic from the first temperature sensor and thesecond temperature characteristic from the second temperature sensor.The field processing module includes a field diagnostic component and afield communication component for communicating with the bitbus and isconfigured for generating field operating data including at least one ofa first field diagnostic parameter as a function of the firsttemperature characteristic and a second field diagnostic parameter as afunction of the second temperature characteristic. An auxiliaryprocessing module is configured for communicating with the bitbus andreceiving the generated field operating data and includes an auxiliarydiagnostic component and an auxiliary communication component having afieldbus interface and a gateway component. The auxiliary processingmodule is configured for generating auxiliary field data as a functionof the received field operating data and for communicating the auxiliaryfield data over a fieldbus.

In another aspect of the invention, a distributed operations systemhaving integrated diagnostics includes a field device such as a sensoror an actuator for generating a field operating characteristic. Thesystem also includes a field processing module connected to the fielddevice for receiving the field operating characteristic from the fielddevice. The field processing module includes a field diagnosticcomponent and a field communication component and is configured forgenerating field operating data, including a field diagnostic parameteras a function of the field operating characteristic. The system alsoincludes a bitbus for communication with the field processing module andfor receiving the field operating data from the field processing module.The system further includes an auxiliary processing module forcommunicating with the bitbus and for receiving the field operatingdata. The auxiliary processing module includes an auxiliary diagnosticcomponent and an auxiliary communication component that includes afieldbus interface and a gateway component. The auxiliary processingmodule is configured for generating auxiliary field data as a functionof the field operating data and for communicating the auxiliary fielddata over a fieldbus.

In another aspect of the invention, a temperature sensing anddiagnostics system having a temperature sensor for generating atemperature characteristic includes a field processing module adaptedfor coupling to the temperature sensor and for receiving the temperaturecharacteristic from the temperature sensor. The field processing moduleincludes a field diagnostic component and a field communicationcomponent. The field processing module is adapted to generate fieldoperating data including a temperature diagnostic parameter as afunction of the temperature characteristic. The system further includesa bitbus for communicating with the field processing module and forreceiving the field operating data from the field processing module. Thesystem also includes an auxiliary processing module for communicatingwith the bitbus and for receiving the field operating data. Theauxiliary processing module includes an auxiliary diagnostic componentand an auxiliary communication component having a fieldbus interface anda gateway component. The auxiliary processing module is configured forgenerating auxiliary field data as a function of the field operatingdata and for communicating the auxiliary field data over a fieldbus.

In yet another aspect of the invention, a method associated with anoperational system includes a field device, a field processing moduleconnected to the field device, a bitbus in communication with the fieldprocessing module, a fieldbus, and an auxiliary processing modulecommunicating with the bitbus and the fieldbus, includes generating afield operating characteristic at the field device and processing thefield operating characteristic at the field processing module. Themethod also includes generating field operating data, including a fielddiagnostic parameter as a function of the field operatingcharacteristic. The method further includes communicating the fieldoperating data including the field diagnostic parameter over the bitbusfrom the field processing module to the auxiliary processing module. Themethod also includes generating at the auxiliary processing moduleauxiliary field data as a function of the received field operating dataand communicating the auxiliary field data over the fieldbus.

In still another aspect of the invention, a method associated with atemperature sensing system includes a temperature sensor, a fieldprocessing module connected to the temperature sensor, a bitbus incommunication with the field processing module, a fieldbus, and anauxiliary processing module communicating with the bitbus and thefieldbus, includes generating a temperature characteristic at thetemperature sensor and processing the temperature characteristic at thefield processing module. The method also includes generating fieldoperating data, including a temperature diagnostic parameter as afunction of the temperature characteristic, and communicating the fieldoperating data including the temperature diagnostic parameter over thebitbus from the field processing module to the auxiliary processingmodule. The method further includes generating at the auxiliaryprocessing module auxiliary field data as a function of the receivedfield operating data and communicating the auxiliary field data over thefieldbus.

Further aspects of the invention will become apparent from the detaileddescription provided hereinafter. It should be understood that thedetailed description and specific examples, while indicating thepreferred embodiment of the invention, are intended for purposes ofillustration only and are not intended to limit the scope of theinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings:

FIG. 1 is a block diagram of a distributed diagnostics monitoring andcontrolling system according to one embodiment of the invention;

FIG. 2 is a block diagram of a field processing module monitoring anddiagnostic system according to another embodiment of the invention;

FIG. 3 is a block diagram of a field processing module system includingpeer-to-peer inter-working over a bitbus according to one embodiment ofthe invention;

FIG. 4 is a block diagram of a fieldbus operational system with multipleauxiliary processing modules and an operational process managementsystem according to one embodiment of the invention;

FIG. 5 is a block diagram of a field device operational environmentsystem according to one embodiment of the invention; and

FIG. 6 is a block diagram of an operations environment with distributeddiagnostic system according to one embodiment of the invention.

Corresponding reference characters indicate corresponding partsthroughout the several views of the drawings.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The following description is merely exemplary in nature and is notintended to limit the invention, its applications, or uses.

In one embodiment, a distributed operations system with integrateddiagnostics includes a field device for generating a field operatingcharacteristic. The system also includes a field processing modulecoupled to the field device for receiving the field operatingcharacteristic from the field device. The field processing moduleincludes a field diagnostic component and a field communicationcomponent and is configured for generating field operating dataincluding a field diagnostic parameter as a function of the fieldoperating characteristic. The system also includes a bitbus forcommunication with the field processing module and for receiving thefield operating data from the field processing module. The systemfurther includes an auxiliary processing module for communicating withthe bitbus and for receiving the field operating data. The auxiliaryprocessing module includes an auxiliary diagnostic component and anauxiliary communication component that includes a fieldbus interface anda gateway or protocol conversion component. The auxiliary processingmodule is configured for generating auxiliary field data as a functionof the field operating data and for communicating the auxiliary fielddata over a fieldbus.

Referring to FIG. 1, a distributed monitoring, controlling anddiagnostics system 100 according to one embodiment of the invention isillustrated. The system 100 can be any type of system requiringmonitoring and controlling that can include, by way of example, afabrication system, a manufacturing system, an assembly system, aprocessing system, an energy management system, a predictive maintenancesystem, a test system, a packaging system, and an operational controlsystem. The system 100 includes one or more field devices 102 shown asfield devices 102A to 102N, one or more field processing modules 106Aand 106B, one or more bitbuses 112A to 112N, an auxiliary processingmodule 118, and a fieldbus 124.

A field device 102 can be any type of device for placement in anoperational system or process. The field device 102 can include, by wayof example, a temperature sensor, a pressure sensor, a flow sensor, alevel sensor, a force sensor, a liquid detection sensor, a stresssensor, a motion sensor, a position sensor, a voltage sensor, a currentsensor, a chemical property sensor, an actuator, a leak sensor, anaccelerometer, a velocimeter, a valve positioner, a valve positionsensor, an RFID tag, a smart card, a gauge including a pressure gauge, asolenoid, a power supply, a heater, a valve including a solenoid valve,a meter, a motor, a pump, a switch including a thermal switch, a Halleffect sensor, a magnetic intensity sensor, a gas sensor, an alert, afusible link, an RFID tag, a smart card, a memory, among other devicesused in factories, process plants, and semiconductor fabricationfacilities. Such field devices 102 can also include a field devicememory (not shown) or indicia that store data or parameters associatedwith the field device 102 or its application. As illustrated, in anoperational implementation, a plurality of field devices 102A-N aredeployed for sensing, actuating, and generating one or more fieldoperational or operating characteristics 105A to 105N via one or morefield device facilities 104A or communication links. The field device102 and the field device facility 104A can be analog or digital.

One or more operating characteristics 105A to 105N can be any type ofcharacteristic provided by one of the above identified field devices102. The field operating characteristics 105 can include by way ofexample, in one form or another, a resistance, a current, a voltage, aHall effect voltage, an energy, a mass, a power, including an electricalpower, a capacitance, an inductance, a reluctance, a phase, a timing, afrequency, a time, a mode, a status, a failure, a position, a state, amagnetic intensity, data, and a parameter. In some embodiments, one ormore of these operating characteristics can be representative of one ormore other operating characteristics. For example, the operatingcharacteristic 105 can be a resistance indicative of a sensedtemperature when the field device 102 is a temperature sensor such as aresistance temperature detector (RTD), a thermopile, a resonancetemperature sensor, an infrared sensor, and a thermistor. Additionally,the field device 102 can be operative to generate field operatingcharacteristic 105 that is coded or encoded such that the code isrepresentative of the field operating characteristic 105 such as oneencoded in a bar code format, a radio frequency identification format,data matrix, or a smart card format.

The field device 102 can be associated with one or more operatingprocesses or systems such as those illustrated as 130A to 130N and 132.The field device 102 communicates field operating characteristic 105associated with the field device 102 and/or operating process or system130 and 132 to a field processing module 106. The field processingmodule 106 includes a field device communication module 108 with aninterface to communicate with the field device 102 and receive fieldoperating characteristic 105. The field processing module 106 furtherincludes a bitbus module or interface 110 for interfacing andcommunicating with a bitbus 112, which can include a bitbus modem. Thefield processing module 106 can also include other components not shown,including a processor, a memory, and software code or programs as willbe discussed later.

The field processing module 106 generates a field operating data 111that includes a field diagnostic parameter 113 as a function of thefield operating characteristic 105. In some embodiments, the fielddiagnostic parameter 113 can be stored in a memory associated with thefield processing module 106 or can be stored in the memory associatedwith the field device 102. The field operating data 111 can beconfigured to any type of configuration or format and, in oneembodiment, can be compliant with a known industry standard such as IEEE1451 and IEEE 1451.4. In an another embodiment, the field processingmodule 106 and the field device 102 are a single component, physicalstructure or mechanically integrated unit as shown in FIG. 3 as combinedunit 302.

The bitbus 112 can be any bitbus including one compliant with acommunication interface. The bitbus 112 can operate as analog, digital,or a combination of the two. In some embodiments, the bitbus 112 isconfigured as a single wire communication medium. Examples of knownbitbus systems include a Dallas Semiconductor one-wire protocol, aSeriplex, a sensor bus, a DeviceNet™ bus, a FMS, Lon Works, a CarAutomotive Network (CAN), an Interbus S, a SDLC, AS-Interface (AS-i), aLocal Interconnect bus (LIN-bus), and a IEEE-1118 bus. In oneembodiment, the bitbus 112 is a communication format that includes lessthan or equal to 8 bits. In another embodiment, a single bit in thebitbus protocol is representative of a field diagnostic parameter, fieldoperating data 111, or the field operating characteristic 105.

The field processing module 106 can also include a field module memory114, a field diagnostic component 115, and a field module processor 116or processing unit. The field memory 114 can store one or more fieldadministrative parameters and can include two related fieldadministrative parameters such as a field diagnostic parameter.Additionally, the field memory 114 can store the received fieldoperating characteristic 105. The field module processor 116 can includea microprocessor for processing the field operating characteristic and afield diagnostic component including at least one of an algorithm, aprogram, an artificial intelligence module, a neural network, a modelingmodule, a mapping, a graphical analysis, a rule, a fuzzy rule, a neuralfuzzy model, a wavelet, a comparator, and a look-up table. The fielddiagnostic component 115 can include an algorithm, a program, anartificial intelligence module, a neural network, a modeling module, amapping, a graphical analysis, a rule, a fuzzy rule, a neural fuzzymodel, a comparator, and a look-up table. These can include any numberof operational or computational operations. For example, in oneembodiment of field diagnostic component 115, the field diagnosticcomponent 115 may be an algorithm, a neural network, empirical data,numerical data, table look-up, fuzzy logic circuit, a wavelet, a neuralfuzzy circuit, a polynomial algorithm, a residual life algorithm, anartificial intelligence module, a modeling module, a statisticalfunction, and/or a loop current step response.

The field processing module 106 is configured to receive the fieldoperating characteristic 105 and to generate a field operating data 111that includes a field diagnostic parameter 113 as a function of thefield operating characteristic 105. Field operating data can optionallyinclude the field operating characteristic 105. The field processingmodule 106 communicates the operating data 111 over the bitbus interface110 to the bitbus 112.

The field diagnostic parameter can be any type of parameter including anoperational diagnostic, a device calibration, equipment diagnostic, aprocess diagnostics, a system administration diagnostic or command, anda system operation. Additionally, the field diagnostic parameter can beany diagnostic parameter including an event, a status, a failure, analert, a mode, and a state. The field processing module 106 can beconfigured to determine the field diagnostic parameter as a function ofthe received field operating characteristic 105.

Additionally, the field processing module 106 can be configured toperform one or more operational functions associated with one of fielddevices 102, the field processing module 106, the bitbus 112, and thesystem 100. The field processing module 106 can perform an operationalfunction, that can include by way of example, a device powering, adiagnostics, trouble shooting method, a statistical process control(SPC) computed parameter, fault detection, fault isolation, a rootcause, a setting, a limit, a threshold, a calibration, a failureprediction, a maintenance procedure, a validation, a verification, atraceability, an auto-configuration, a system or architecture alignment,a fingerprint, an identification, a biometric identification, atheoretical modeling, a self-administration, and a self-tuning rule,model or algorithm, among others.

For example, where the field device 102 is a temperature sensor, thefield processing module 106 can be configured to determine a sensedtemperature as a function of field operating characteristic 105 and afield temperature diagnostic parameter. The field processing module 106can determine the sensed temperature as a function of anEMF-to-temperature relationship defined by the field or temperaturediagnostic parameter. Additionally, the field processing module 106 candetermine a thermal characteristic of the field device 102 as a functionof field operating characteristic 105. Where the field operatingcharacteristic 105 can be a temperature characteristic indicative of asensed energy level. As such, the field processing module 106 cancompare the sensed energy level to a predefined energy level andidentify a temperature diagnostic event when the difference between thesensed energy level and the predefined energy level is indicative of thetemperature diagnostic event. Similarly, the field diagnostic componentcan be configured to determine a change in isothermal entropy.

In another embodiment, the field device 102 can be a heater and thefield operating characteristic 105 is a heater characteristic.

In another embodiment, the field processing module 106 generates fieldoperating data 111 in response to a field operating event or occurrenceor can continuously provide the field operating data 111. In oneoptional embodiment, field processing module 106 is configured todetermine the occurrence of at least one operating event, anadministrative event, and/or a maintenance event. Examples of fieldoperating events include, by way of example, a change of a state, achange of a mode, a change of a status, a failure, a change of a fieldparameter, a change of the field operating characteristic, a time rateof change of a temperature characteristic (first derivative), a value ofa field parameter exceeding a threshold, and a value of the fieldoperating characteristic exceeding a threshold.

In other embodiments, the field processing module 106 can include one ormore other operational components such as an analog-to-digitalconversion component (not shown). In such a case, the field device 102can generate the field operating characteristic 105 in an analog format.The field processing module 106 receives the analog format and generatesthe field operating data 111 in a digital format. The field processingmodule 106 can also include a data compression component for compressinga portion or all of the field operating data 111 for communication overthe bitbus 112. Such data compression can include a table mapping, analgorithm, and/or a coding. The field processing module 106 can furtherinclude a data encryption component for encrypting some or all of thedata transmitted over the bitbus 112. In another embodiment, the fieldprocessing module 106 provides a digital-to-digital conversion when thefield device 102 communicates digitally with the field processing module106.

As an example of coding, the data compression component is configuredfor mapping the field diagnostic parameter to a prime number forcommunication over the bitbus 112. In such a case, a diagnosticcharacter mapping or coding can increase the data transfer bandwidth ofthe bitbus 112 between the field device 102 and the field processingmodule 106. Two or more diagnostic parameters are associated with two ormore diagnostic conditions of the field device 102 or the fieldprocessing module 106. The field processing module 106 provides formapping each diagnostic parameter to a separate prime number in thefield processing module 106. When the field processing module 106determines that one or more of the diagnostic conditions exist, each ofthe associated prime numbers for those diagnostic conditions are storedand multiplied to determine a product number of each of the applicableprime numbers. The product number is transmitted to an auxiliaryprocessing module 118 over bitbus 112. At the auxiliary processingmodule 118, the single product number is received and factored todetermine the prime numbers and therefore the applicable diagnosticconditions identified by the field processing module 106. By multiplyingeach applicable prime number and transmitting the single product number,the current system provides for communication of the full set ofdiagnostic conditions within the restricted bandwidth of the bitbus 112.

In another embodiment, the field processing module 106 can be configuredto generate a field administrative parameter 142 and communicate thefield administrative parameter 142 to the field device 102. The fieldprocessing module 106 may also use an embedded function block withstandardized and/or customized parameters. The field administrativeparameter 142 can be any type of parameter, including a request, aquery, or a command related to the administration or operation of thefield device 102. In such an embodiment, the field device 102 wouldrespond by generating the field operating characteristic 105 as afunction of the received field administrative parameter 142. Inoperation, the field processing module 106 can generate the fieldadministrative parameter 142 in response to an operating event, anadministrative event, and/or a maintenance event, among others. Thefield administrative parameter 142 can be an instruction and/or a query.Alternatively, the field processing module 106 can generate the fieldadministrative parameter 142 in response to receiving an auxiliaryadministrative parameter over the bitbus 112 from another entity such asanother field processing module 106 or an auxiliary processing module118.

In another embodiment, the system 100 includes a first field processingmodule 106A and a second field processing module 106B. The second fieldprocessing module 106B generates a second field operating data 111B andcommunicates with the bitbus 112. The second field processing module106B communicates second field operating data 111B to the first fieldprocessing module 106A over the bitbus 112 in a peer-to-peer fieldprocessing module communication. Additionally, as auxiliary processingmodule 118 is coupled to the bitbus 112. The auxiliary processing module118 can monitor peer-to-peer field processing module communicationsbetween two or more field processing modules 106. In such an embodiment,the auxiliary processing module 118 can initiate an administrativeaction, command, or message in response to the monitored peer-to-peerfield processing module communications.

Similarly, a second field device 102B generates a second field operatingcharacteristic 105B. The second field processing module 106B receives asecond field operating characteristic 105B from the second field device102B. The second field processing module 106B has a second fielddiagnostic component 115B and a second field communication component.The second field processing module 106B communicates with first fieldprocessing module 106A, a second administrative parameter, second fieldoperating data 111B, a second field diagnostic parameter, and/or secondfield operating characteristic 105B. Additionally, as discussed above,the auxiliary processing module 118 can monitor the communication of theadministrative parameter and/or operating data and can initiate anadministrative action, command, or message in response to the monitoredadministrative parameter and/or operating data communications. As willbe discussed, in alternative embodiments other field processing module106 to the field processing module 106 peer-to-peer inter-workings andinteractions are possible as illustrated in FIG. 3 as system 300.

As in FIG. 1, in yet another embodiment a first field device 102A and asecond field device 102B can be coupled to a single or the same fieldprocessing module 106A. The second field device 102B generates secondfield operating characteristic 105B and field processing module 106Areceives second field operating characteristic 105B and communicates thesecond field operating characteristic 105B to the first field device102A. FIG. 2 illustrates system 200 that includes various peer-to-peerfield devices 102 inter-working according to some additional embodimentsof the invention.

Referring again to FIG. 1, the auxiliary processing module 118 includesa bitbus communication component 120 for interfacing with andcommunicating over the bitbus 112. Additionally, the auxiliaryprocessing module 118 includes a fieldbus communication component 122(or network communication component) for interfacing with andcommunicating over the fieldbus 124. The auxiliary processing module 118can include an auxiliary module processor 126, an auxiliary modulememory 128, an auxiliary diagnostic component 134, and an auxiliarygateway component 136. The auxiliary processing module 118 communicateswith the bitbus 112 for receiving the field operating data 111. Theauxiliary processing module 118 is configured to generate an auxiliaryfield data 138 as a function of field operating data 111 generated bythe field processing module 106 and to communicate auxiliary field data138 over the fieldbus 124. Optionally, the auxiliary processing module118 can include an auxiliary diagnostic parameter, and generates theauxiliary field data 138 as a function of the auxiliary diagnosticparameter. In such a case, the auxiliary field data 138 can include theauxiliary diagnostic parameter. The auxiliary diagnostic parameter canbe an operational diagnostic, a device calibration, a systemadministration, and a system operation. Also optionally, the auxiliaryprocessing module 118 can also generate and /or communicate an auxiliaryadministrative parameter over the bitbus 112 to the field processingmodule 106.

The auxiliary module processor 126 can be a microprocessor havingcomputer readable instructions including at least one of an algorithm, arule, an artificial intelligence module, a modeling module, a mapping, agraphical analysis, a comparator, and a look-up table. The auxiliaryprocessing module 118 can include an algorithm or similar functioningcircuit or program that can include a neural network, an empirical data,a numerical data, a look-up table, a fuzzy logic circuit, a neural fuzzycircuit, a wavelet, a polynomial algorithm, a residual life algorithm,an artificial intelligence module, a modeling module, and a statisticalfunction. In another embodiment, auxiliary diagnostic component 134 caninclude an algorithm, a rule, an artificial intelligence module, amodeling module, a mapping, a graphical analysis, a comparator, and alook-up table. The auxiliary module memory 128 can store the auxiliaryparameter such as an auxiliary diagnostic parameter.

With one or more of these embodiments, auxiliary processing module 118can be configured to perform an operational function associated with thefield device 102, the field processing module 106, the bitbus 112, theauxiliary processing module 118, the fieldbus 124, and the system 100.The operational function can be any operational function including adiagnostics, a trouble shooting method, a statistical process control(SPC) computed parameter, a fault detection, a fault isolation, a rootcause, a setting, an alert, an alarm, a comparison, a limit, threshold,a calibration, a failure prediction, a maintenance procedure, avalidation, a verification, a traceability, an auto-configuration, asystem or architecture alignment, a fingerprint, an identification, abiometric identification, a theoretical modeling, a self-administration,and a self-tuning rule.

The auxiliary processing module 118 can generate and/or communicate anauxiliary administrative parameter to the field processing module 106over the bitbus 112. Such generation of the auxiliary administrativeparameter can be in response to an auxiliary administrative event or anadministrative instruction received over the fieldbus 124. The auxiliaryprocessing module 118 can also provide electrical power to bitbusconnected devices.

The auxiliary processing module 118 can also include a protocolconverter component, a data concentrator component, an administrativecomponent, an encryption component, and an inter-field processing modulecommunication component. The protocol converter component can includecapabilities for a conversion from a bitbus format to one or morefieldbus or network protocols. The data concentrator component couldprovide for concentrating data through coding or mapping or algorithm inorder to concentrate transmitted data over the bitbus 112 or thefieldbus 124. Additionally, auxiliary processing module 118 can alsoinclude a data encryption component to provide for encrypting data toprovide for increased security in the factory and process controlsystems.

The fieldbus 124 can include a communication format greater than 8 bits.For example, the fieldbus 124 can include a Profibus, an enterprisecommunication bus including an Ethernet TCP/IP, an Internet, a tokenring LAN, an Ethernet LAN, an FDDI network, a private data network, anISDN, a wireless network such as IEEE 802.11a, 802.11b or 802.11g,Zigbee, or WiMax, and a VPN. Additionally, the auxiliary bitbuscommunication component 120 can include a bitbus modem and the auxiliaryfieldbus communication component 122 can include a fieldbus modem. Thefieldbus 124 can utilize a variety of physical layer systems includingwire, fiber, and wireless systems.

Additionally, as the field processing module 106 and the auxiliaryprocessing module 118 are each communicating over the bitbus 112, eachcan be configured to interoperate to cooperate to perform an operationalfunction on a distributed basis on behalf of or associated with thefield device 102, the field processing module 106, the auxiliaryprocessing module 118, the bitbus 112, and the system 100. Thecooperative operational function can be a diagnostic, a trouble shootingmethod, a statistical process control (SPC) computed parameter, a faultdetection, a fault isolation, a root cause, a setting, a limit, analarm, a comparison, an alert, a threshold, a calibration, a failureprediction, a maintenance procedure, a validation, a verification, atraceability, an auto-configuration, an architecture alignment, afingerprint, a biometric identification, an identification, atheoretical modeling, a self-administration, and a self-tuning rule.

As discussed above, in some embodiments system 100 includes the firstfield device 102A, the first field processing module 106A, the secondfield device 102B generating second field operating characteristic 105B,and the second field processing module 106B also communicating with thebitbus 112. The second field processing module 106B receives the secondfield operating characteristic 105B from the second field device 102Band generates a second field operating data 111B including a secondfield diagnostic parameter as a function of second field operatingcharacteristic 105B. The auxiliary processing module 118 receives secondfield operating data 111B. The auxiliary processing module 118 alsoincludes a supervisory module that generates supervisory data as afunction of first field operating data 111A and second field operatingdata 111B. The auxiliary processing module 118 communicates thesupervisory data over the fieldbus 124.

In another embodiment, the system 100 includes second field processingmodule 106B coupled to the second field device 102B and is coupled to asecond bitbus 112B. The second bitbus 112B can also be coupled to thesame auxiliary processing module 118 to which the first bitbus 112A arecoupled. The auxiliary processing module 118 communicates with thesecond bitbus 112B and the first bitbus 112A. The auxiliary processingmodule 118 communicates to the first field processing module 106A one ormore of a second administrative parameter, the second field operatingdata 111B, the second field diagnostic parameter, the second fieldoperating characteristic 105B, and the field administrative parameter142.

Referring to FIG. 4, a fieldbus operational system 400 with multipleauxiliary processing modules 118 and an operational process managementsystem according to one embodiment of the invention. As illustrated,that first auxiliary processing module 118A and the second auxiliaryprocessing module 118B are each coupled to the fieldbus 124. In such asituation, the second auxiliary processing module 118B can generate anadministrative instruction and communicate the administrativeinstruction over the fieldbus 124 to the first auxiliary processingmodule 118A.

In one embodiment, the system 400 has a first field device 102A, firstbitbus 112A, the first field processing module 106A and the firstauxiliary processing module 118A. The system 400 also has a second fielddevice 102B generating a second field operating characteristic 105B, asecond field processing module 106B generating second field operatingdata 111B including a second field diagnostic parameter as a function ofthe second field operating characteristic 105B. The system 400 also hasa second bitbus 112B communicating with the second field processingmodule 106B. A second auxiliary processing module 118B communicates witha second bitbus 112B and has a second fieldbus interface communicationcomponent 122B or interface for communicating over the fieldbus 124. Insuch an embodiment, the second field processing module 106B communicateswith the first field processing module 106A via the second bitbus 112B,the second auxiliary processing module 118B, the fieldbus 124, the firstauxiliary processing module 118A, and the first bitbus 112A.

Additionally, the auxiliary processing modules 118A and 118B can beconfigured for communicating auxiliary field data 138 over the fieldbus124 to a field operations management system 402 which is also coupled tothe fieldbus 124. The field operations management system 402 can be anytype of management or administrative system for managing one or moreoperational functions of the operating system, operating environment, orsystem 100. For example, this can be a temperature management system forreceiving and managing a plurality of temperature sensors.

The field operations management system 402 can include a fieldbusinterface or communication module 404, a processor 406, a memory 408, amonitoring module 410, a diagnostic module 412, and an operations systemmodule or interface 414. The operations system interface 414 interfacesto a communication facility 418 or operations system interface link thatcommunicates with an operations system 416. The operations system 416can be any operations, administration, controlling, or monitoring systemincluding those known in the industry, by way of example, an AssetManagement System, a SCADA system, a building energy management system,and a test system.

The field operations management system 402 can be configured to receivethe auxiliary field data 138 and generating a field device controlinstruction as a function of the received auxiliary field data 138. Thefield operations management system 402 can also be configured forperforming an operational function associated with the field device 102and/or system 100 such as a diagnostics, a trouble shooting, a faultdetection, a fault isolation, a root cause, a setting, an alarm, acomparison, an alert, a limit, a threshold, a calibration, a failureprediction, a maintenance procedure, a validation, verification, atraceability, an auto-configuration, an architecture alignment, afingerprint, a biometric identification, an identification, atheoretical modeling, a self-administration, a self-tuning rule, and anoperational device control. For example, the field operations managementsystem 402 can generate an administrative instruction to one or moreauxiliary processing modules 118, the field processing modules 106, orthe field device 102.

Referring now to FIG. 5, a field device operational environment system500 is illustrated. The field device 102 can be in proximity to fieldprocess or system 130 as illustrated with 102A in association withprocess 130A, or located on or in a process as illustrated as 102B inprocess 130B. In this embodiment, the process 130A is coupled viacontrol facility 502 to operations system 416A for receiving operationalcontrol instruction or command 503. The operations system 416A iscoupled to the operations management system 402 via the communicationfacility 418 and to an operations communication facility 504 forinterfacing to other operations systems such as operations system 416Bfor receiving instruction or command 505A.

Similarly, the field process 130B is coupled to the operations system416B via operational link 506 for receiving process input 507. Theoperations system 416 is also coupled to operations communicationfacility 504 for receiving instruction 505B. Additionally, theoperations system 416B is coupled to process source 510 via processinput source 508. The operations system 416B provides a portion ofprocess input source 508 to process system 130B via the operational link506 as process input 507.

Referring now to FIG. 6, an operations environment with a distributeddiagnostic system 600 is illustrated as one embodiment. Operationalmanagement system 602 communicates with a plurality of operationssystems 416B and 416C, a field device controller 604B, and the auxiliaryprocessing module 118.

In one embodiment, an operational device can be a heater coupled to aheater power circuit for receiving heating power from a power supply.The heater power circuit has a first interface, a second interface, andan intermediate portion between the first interface and the secondinterface. A power controller is coupled about the intermediate portionof the heater power circuit. The power controller has at least twostates with a first state providing a portion of the power to the heaterand a second state terminating power to the heater. The power controllerincludes the field device 102 and field processing module 106. In suchan embodiment, the heater is in thermal proximity to the field device102 which can be a temperature sensor. Field diagnostic component 115 offield processing module 106 can be configured to determine a mass flowin the heater as a function of the temperature characteristic.

In operation, embodiment of the invention can be implemented as a methodof diagnosing a distributed operational system. In such a case, a methodcan include generating field operating characteristic 105 at the fielddevice 102 and processing field operating characteristic 105 at fieldprocessing module 106. The method further includes generating fieldoperating data 111 including a field diagnostic parameter as a functionof field operating characteristic 105 and communicating field operatingdata 111 including the field diagnostic parameter over the bitbus 112from field processing module 106 to the auxiliary processing module 118.The method also includes generating at the auxiliary processing module118 auxiliary field data 138 as a function of received field operatingdata 111 and communicating the auxiliary field data 138 over thefieldbus 124.

In another implementation, a method of diagnosing a temperature sensingsystem includes a temperature sensor field device 102 generating fieldoperating characteristic 105. The field processing module 106 generatesthe field operating data 111 including a temperature diagnosticparameter as a function of the temperature characteristic andcommunicates the field operating data 111 including the temperaturediagnostic parameter over the bitbus 112 to the auxiliary processingmodule 118. The method further includes generating at the auxiliaryprocessing module 118 the auxiliary field data 138 as a function ofreceived field operating data 111 and communicating the auxiliary fielddata 138 over the fieldbus 124.

Some embodiments of the invention provide a distributed diagnosticscomputing architecture not currently available. The field device digitalinformation is limited by the small message size and bandwidth of thebitbus 112. The limitations of the bitbus 112 are overcome by providinglow level data related to the sensor, process, circuit, or thermal loopthat is processed by the field processing module 106 and an auxiliaryprocessing module 118 that includes a gateway function. The diagnosticscircuit in the auxiliary processing module 118 can include amicroprocessor, a memory and one or more algorithms for processing thebit level diagnostics parameters. The bit level parameters are processedby a diagnostics circuit and algorithm that can include: a neuralnetwork, a look-up table, a fuzzy logic circuit, a neural fuzzy circuit,a polynomial algorithm, a residual life algorithm, and/or a statisticalfunction. The auxiliary processing module 118 may also interface tomultiple sensors or actuators and contact multiple diagnostic circuits.

A field processing module 106 and the auxiliary processing module 118working in conjunction with the bitbus 112 provide significantly lowercost monitoring and controlling solutions for operational systems andcan include utilizing previously installed bitbus communicationssystems. Embodiments of the invention can provide added value anddiagnostic functionality to existing monitoring and controlling systemswithout full replacement and rewiring of sometimes complex systems andimplementations.

One or more of the embodiments of the invention provides for thedistribution of diagnostic information processing between the fielddevice 102 or sensor, the field processing module 106, and the auxiliaryprocessing module 118 to provide for simplifying the sensor located inthe operations process or system without requiring the implementationand deployment of expensive fieldbus systems. This system provides foruse of the bitbus 112 to deliver the parameters required for diagnosticsof the sensing system.

One or more embodiments described above can be operable in a variety ofoperational environments and situations. For example, one implementationof system 100 includes an energy balance application. In such animplementation, the field device 102 monitors energy flow in and out ofan operational system. The field processing module 106 determines theenergy transformed within operational system and stores efficiencyparameters in the field memory 114. The field processing module 106compares the energy in, the energy out, and the transformed energy usinga diagnostic module or circuit including an algorithm and identifies anenergy imbalance in the operating system or system 100. For example, anenergy event can be identified when one of the energies or the energyimbalance is greater than a predetermined energy threshold. When suchimbalance occurs, the field processing module 106 can generate an alarmto provide a message to the auxiliary processing module 118 includingindicating the source of the imbalance and detailed data related to it.

In another example, the system 100 can operate to determine anisothermal entropy change. In such an implementation, the field device102 measures a temperature of a field working unit such as a containerfor holding goods which is ideally near their freezing point. The fielddevice 102 and/or the field processing module 106 characterizing theenergy flow into and out of the container. The field processing module106 compares the energy flow to the rate of temperature change of thecontainer and identifies an energy flow condition such that the energyflow is greater than an energy flow threshold corresponding to a changein temperature of the container.

In yet another example, the system 100 can operate to determine anenergy flow in a heater system with mass flow. In such animplementation, the system 100 measures the temperature of a processhaving mass flow. The system can provide for a heating of the processand a measurement of the resulting mass flow of the process. The fieldprocessing module 106 transmits the measured temperature and measuredmass flow over the bitbus 112 to the auxiliary processing module 118.The auxiliary processing module 118 compares the calculated temperaturerise to a given heater power input and generates a status message or analarm message to indicate a mismatch between the calculated temperatureand the measured temperature.

In another example of system 100, the system 100 operates a loop currentstep response (LCSR) method. In such an implementation, a temperaturesensor is heated as an administrative action. A loop current stepresponse test is performed and the measurements or field operatingcharacteristics 105 are generated. The field processing module 106receives the test results and characterizes the self heating data withat least a first order time constant utilizing an algorithm. The fieldprocessing module 106 stores the first order time constant from thecharacterizing in the field memory 114. The field processing module 106compares the stored time constant to a current time constant from anLCSR test. A message, status or signal can be generated such as when thecomparison is indicative of a change event or a change from the initialconditions.

Generally, the field processing module 106 and the auxiliary processingmodule 118 include an operating environment that can include a computersystem with a computer that comprises at least one central processingunit (CPU), in conjunction with a memory system, an input device, and anoutput device. These elements are interconnected by at least one busstructure.

The CPU can be of familiar design and includes an arithmetic logic unit(ALU) for performing computations, a collection of registers fortemporary storage of data and instructions, and a control unit forcontrolling operation of the system. Any of a variety of processors,including at least those from Digital Equipment, Sun, MIPS, Atmel,Motorola, NEC, Intel, Cyrix, AMD, HP, and Nexgen, is equally preferredfor the CPU. The illustrated embodiment of the invention operates on anoperating system designed to be portable to any of these processingplatforms.

The memory system can generally include high-speed main memory in theform of a medium such as random access memory (RAM) and read only memory(ROM) semiconductor devices, and secondary storage in the form of longterm storage mediums such as floppy disks, hard disks, tape, CD-ROM,flash memory and other devices that store data using electrical,magnetic, optical or other recording media. The main memory can alsoinclude video display memory for displaying images through a displaydevice. Those skilled in the art will recognize that the memory systemcan comprise a variety of alternative components having a variety ofstorage capacities.

The input device can comprise, by way of example, a keyboard, a mouse, asmart card, a voice activated module, and a physical transducer (e.g. amicrophone). The output device can comprise a display, a printer, atransducer/speaker. Some devices, such as a network adapter or a modem,can be used as input and/or output devices.

As is familiar to those skilled in the art, the computer system furtherincludes an operating system and at least one application program. Theapplication can perform one or more of the functions described above.The operating system is the set of software which controls the computersystem's operation and the allocation of resources. The applicationprogram is the set of software that performs a task desired by the user,using computer resources made available through the operating system.Both are resident in the illustrated memory system.

In accordance with the practices of persons skilled in the art ofcomputer programming, embodiment of the invention is described abovewith reference to symbolic representations of operations that areperformed by the computer system. Such operations are sometimes referredto as being computer-executed or computer executable instructions. Itwill be appreciated that the operations which are symbolicallyrepresented include the manipulation by the CPU of electrical signalsrepresenting data bits and the maintenance of data bits at memorylocations in the memory system, as well as other processing of signals.The memory locations where data bits are maintained are physicallocations that have particular electrical, magnetic, or opticalproperties corresponding to the data bits. The invention can beimplemented in a program or programs, comprising a series ofinstructions stored on a computer-readable medium. The computer-readablemedium can be any of the devices, or a combination of the devices,described above in connection with the memory system.

Additionally, the bitbus 112 and the fieldbus 124 and each of the aboveidentified communication modules and/or interfaces can be compatiblewith a hard-wired electrical communication facility, an opticalfacility, a wireless facility, a wireless telephonic facility, and asatellite facility.

When introducing aspects of the invention or embodiments thereof, thearticles “a”, “an”, “the”, and “said” are intended to mean that thereare one or more of the elements. The terms “comprising”, “including”,and “having” are intended to be inclusive and mean that there can beadditional elements other than the listed elements.

In view of the above, it will be seen that several advantages areachieved and other advantageous results attained. As various changescould be made in the above exemplary constructions and methods withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

It is further to be understood that the processes or steps describedherein are not to be construed as necessarily requiring theirperformance in the particular order discussed or illustrated. It is alsoto be understood that additional or alternative processes or steps canbe employed.

1. A temperature sensing and diagnostics system having a temperaturesensor for generating a temperature characteristic and a first bus, thesystem comprising: a field processing module adapted for coupling to thetemperature sensor and for receiving the temperature characteristic fromthe temperature sensor, the field processing module including a fielddiagnostic component that performs a computational operation to generatea field diagnostic parameter as a function of the temperaturecharacteristic and a field communication component configured forcommunication over the first bus; and an auxiliary processing moduleconfigured for communicating with the first bus and for receiving thefield diagnostic parameter, said auxiliary processing module includingan auxiliary diagnostic component that performs a computationaloperation to generate an auxiliary diagnostic parameter, and anauxiliary communication component having a second bus interface and agateway component, said auxiliary processing module being configured forcommunicating the auxiliary diagnostic parameter over a second busseparate and distinct from the first bus wherein the auxiliaryprocessing module is configured for transmitting the auxiliarydiagnostic parameter to the field processing module, and wherein thefield processing module is configured for communicating the fielddiagnostic parameter over the first bus in response to the receivedauxiliary diagnostic parameter.
 2. The system of claim 1 wherein thetemperature characteristic is selected from the group consisting of loopresistance, energy, power, frequency, current, and voltage.
 3. Thesystem of claim 1 wherein the temperature characteristic is a sensedenemy level and wherein the field processing module is adapted tocompare the sensed energy level to a predefined energy level and toidentify a temperature diagnostic event when the difference between thesensed energy level and the predefined energy level is indicative of thetemperature diagnostic event
 4. The system of claim 1 wherein the fielddiagnostic component is configured for determining a change in anisothermal entropy.
 5. The system of claim 1 wherein the fielddiagnostic component is configured for determining a mass flow in aheater as a function of the temperature characteristic, the heater beingin the system and associated with the temperature sensor.
 6. The systemof claim a 1 wherein the field diagnostic component includes a loopcurrent step response.
 7. The system of claim 1 wherein the auxiliaryprocessing module is configured for converting the received fielddiagnostic parameter in a first bus format to the auxiliary diagnosticparameter in a second bus format, and for communicating the auxiliarydiagnostic parameter over the second bus to a temperature managementsystem coupled to the second bus.
 8. The system of claim 1, furthercomprising a field device for generating a field operatingcharacteristic, said field processing module configured for receivingthe field operating characteristic and the field diagnostic componentconfigured for generating the field diagnostic parameter further as afunction of the field operating characteristic.
 9. The system of claim 8wherein the field device is selected from the group consisting of atemperature sensor, a pressure sensor, a flow sensor, a level sensor, aforce sensor, a leak detection sensor, a stress sensor, a motion sensor,a position sensor, a voltage sensor, a current sensor, a chemicalproperty sensor, an actuator, a leak sensor, an accelerometer, avelocimeter, a valve positioner, a valve position sensor, an RFID tag, asmart card, a gauge including a pressure gauge, a solenoid, a powersupply, a heater, a valve including a solenoid valve, a meter, a motor,a pump, a switch including a thermal switch, a Hall effect sensor, amagnetic intensity sensor, a gas sensor, a fusible link, an RFID tag, asmart card, and a memory device.
 10. The system of claim 8 wherein thefield device includes a field device memory storing a field devicediagnostic parameter and wherein the field device is configured toprovide the field device diagnostic parameter to the field processingmodule.
 11. The system of claim 1 wherein the temperature sensor isselected from the group consisting of a thermocouple, a resistancetemperature detector (RTD), a thermopile, a diode, a semiconductorsensor, a resonance temperature sensor, an infrared sensor, and athermistor.
 12. The system of claim 1 wherein the field processingmodule is configured for determining a sensed temperature as a functionof the temperature characteristic and the field diagnostic parameter.13. The system of claim 12 wherein the sensed temperature is determinedas a function of an EMF-to-temperature relationship defined by the fielddiagnostic parameter.
 14. The system of claim 1 wherein the fielddiagnostic component is configured to generate the field diagnosticparameter responsive to a field operating event selected from the groupconsisting of a change of a state, a change of a mode, a change of astatus, a failure, a change of a field parameter, a change of the fieldoperating characteristic, a time rate of change of a temperaturecharacteristic, a value of a field parameter exceeding a threshold, analarm, a comparison, en alert, and a value of the field operatingcharacteristic exceeding a threshold.
 15. The system of claim 1 whereinthe field diagnostic parameter includes a temperature diagnosticparameter.
 16. The system of claim 1 wherein the auxiliary diagnosticparameter is selected from the group consisting of an operationaldiagnostic, a device calibration, a configuration, a controller action,a system administration, and a system operation.
 17. The system of claim1 wherein the auxiliary processing module is configured to perform anoperational function associated with at least one of the temperaturesensor, the field processing nodule, the first bus, the auxiliaryprocessing module, the second bus, and the system, the operationalfunction being selected from the group consisting of a diagnostics, atrouble shooting method, a statistical process control (SPC) computedparameter, a fault detection, a fault isolation, a root cause, asetting, a limit, a threshold, a calibration, a failure prediction, amaintenance procedure, a validation, a verification, a traceability, anauto-configuration, an architecture alignment, a fingerprint, anidentification, a biometric identification, a theoretical modeling, aself-administration, a self-tuning rule, an operational device control.18. The system of claim 1 wherein the temperature sensor and the fieldprocessing module are configured as a mechanically integrated unit. 19.The system of claim 1 wherein the temperature sensor includes atemperature sensor memory storing a temperature sensor diagnosticparameter and wherein the temperature sensor is configured to providethe temperature sensor diagnostic parameter to the field processingmodule.
 20. The system of claim 1 wherein the first bus has acommunication format having less parameters than a communication formatof the second bus.
 21. A temperature sensing system with integrateddiagnostics having a first bus, a temperature sensor for generating atemperature characteristic, and a field device for generating a fieldoperating characteristic, the system comprising: a first fieldprocessing module for receiving the temperature characteristic from thefirst temperature sensor, the first field processing module including afirst field diagnostic component that performs a computational operationto generate a first diagnostic parameter as a function of thetemperature characteristic and a first field communication componentconfigured for communication over the first bus; a second fieldprocessing module for receiving the field operating characteristic fromthe field device, the second field processing module having a secondfield diagnostic component that performs a computational operation togenerate a second diagnostic parameter, and a second field communicationcomponent configured for communication over the first bus; and anauxiliary processing module configured for communicating with the firstbus and receiving the first diagnostic parameter from the first fieldprocessing module and the second diagnostic parameter from the secondfield processing module, said auxiliary processing module including anauxiliary diagnostic component that performs a computational operationto generate an auxiliary diagnostic parameter as a function of at leastone of the first diagnostic parameter and the second diagnosticparameter, and an auxiliary communication component having a second businterface and a gateway component said auxiliary processing moduleconfigured for communicating the auxiliary diagnostic parameter over asecond bus separate and distinct from the first bus.
 22. The system ofclaim 21 wherein the auxiliary field processing module includes asupervisory module generating supervisory data as a function of thefirst diagnostic parameter and the second, said auxiliary fieldprocessing module configured to communicate the supervisory data overthe second bus.
 23. The system of claim 21 wherein the first buscomprises a first bitbus and a second bitbus, wherein the first fieldcommunication component is configured for communication with the firstbitbus and the second field communication component is configured forcommunication with the second bitbus, the auxiliary processing modulebeing configured for communicating with the first bitbus for receivingthe first diagnostic parameter and configured for communicating with thesecond bitbus for receiving the second.
 24. The system of claim 23,further comprising a second auxiliary processing module forcommunicating with the second bitbus and having a second bus interfacefor communicating over the second bus, wherein said second fieldprocessing module is configured to communicate with the first fieldprocessing module via the second bitbus, the second auxiliary processingmodule, the second bus, the first auxiliary processing module, and thefirst bitbus.
 25. The system of claim 21 wherein the first fieldprocessing module is configured to receive the second diagnosticparameter and to transmit the second diagnostic parameter over the firstbus as a function, at least in part, of the received second diagnosticparameter.
 26. The system of claim 21 wherein temperature sensor is afirst temperature sensor for generating a first temperaturecharacteristic and the field device is a second temperature sensor andthe field operating characteristic is a second temperaturecharacteristic.
 27. A temperature sensing system with integrateddiagnostics having a first bus, the system comprising: a firsttemperature sensor configured for generating a first temperaturecharacteristic; a second temperature sensor configured for generating asecond temperature characteristic; a field processing module forreceiving the first temperature characteristic from the firsttemperature sensor and the second temperature characteristic from thesecond temperature sensor, the field processing module including a fielddiagnostic component that performs a computational operation to generatea field diagnostic parameter as a function of at least one of the firsttemperature characteristic and the second temperature characteristic anda field communication component for communicating with the first bus;and an auxiliary processing module configured for communicating with thefirst bus and receiving the field diagnostic parameter, said auxiliaryprocessing module including an auxiliary diagnostic component thatperforms a computational operation to generate an auxiliary diagnosticparameter and an auxiliary communication component having a second businterface and a gateway component, said auxiliary processing moduleconfigured for communicating the auxiliary diagnostic parameter over asecond bus separate and distinct from the first bus.
 28. The system ofclaim 27 wherein the field processing module is configured to transmitthe received second temperature characteristic to the first fieldtemperature sensor.